Clip house for mounting of automotive trim parts

[0001] This application claims the priority filing benefit of International PCT Application PCT/US03/023863 filed Jul. 30, 2003, and published under PCT 21(2) in the English language and U.S. Provisional Application Ser. No. 60/414,315 filed Sep. 27, 2002.

[0002] The present invention pertains to molded plastic parts for attachment to a supporting member. More specifically, the present invention relates to clip house mounting structures which provide improved flexural characteristics and structural strength in the corresponding part.

[0003] Injection molded plastic parts are commonly used in the automotive industry for side panels, spoilers, dashboards, armrests, wheel covers, filler panels, trim pieces, bumpers, side-sill garnishes, rocker panels and the like. Typically these parts are provided with a painted, or other decorative surface such as by means of film lamination techniques. In film lamination techniques, a paint film laminate is co-molded over an external show face surface of the plastic part. The film laminate is typically pre-formed, inserted into a mold cavity, and a thermoplastic resin is injected under pressure into the mold cavity against the backside of the laminate. The result is a plastic part having a film laminate co-molded over a plastic substrate. Laminated paint films are detailed in U.S. Pat. No. 5,514,427, the entire disclosure of which is incorporated by reference herein. Techniques for preforming paint film laminates and insert molding film-plastic parts are disclosed in U.S. Pat. No. 5,599,608, the disclosure of which is incorporated herein by reference.

[0004] The plastic parts are typically provided with a series of integrally molded attachment means or as they are referred to in the art “clip houses” for securing the part to the given support member. Structural strength of the attachment means is dependent upon many factors including the thickness of the plastic at the intersection of the attachment means with the part to be supported.

[0005] One representative mounting structure for an automotive part is shown in U.S. Pat. No. 6,171,543. In this disclosure, a reinforcing rib is interposed between the connection of the clip house structure and the hidden side of the corresponding plastic part. The rib provides the required strength while limiting the thickness of plastic material proximate the show face surfaces of the part.

[0006] Some elongated injection molded automobile parts, such as a rocker panel and side sill garnishes, comprise a top show surface connected to a depending side show surface. In these structures, it is desirable to increase the stability of the side show surface while providing increased flex in the top show surface so that the latter can accommodate weight loads that may be exerted thereon such as by passengers who enter and disembark from the vehicle.

[0007] The rocker panel or side sin garnish with clip house mounting structure combination includes a first support member of the clip house that is connected to the plastic automotive part at a first junction located between the top show surface of the automotive part and the side surface thereof. Desirably, the top show surface extends over this first support member leaving an air space between these members to provide increased flex along the top surface. Most preferably, the first junction and support member are joined along a hollow rib or channel.

[0008] Additionally, a second support member of the clip house is attached to the part along the non show side or backside of the side surface. The second support member is attached to the part as a second junction that separates the side surface of the part from the underside of the part that normally will extend below the frame member. The clip house includes a generally planar attachment leg to which the first and second support are connected.

[0009] The invention will be further described in conjunction with the ensuing detailed description and drawings.

[0012] Referring initially to FIG. 1 there is shown a rocker panel 5 in accordance with the prior art. The rocker panel 5 is shown with a clip house mounting structure 10 connected thereto. Additionally, the rocker panel 5 is shown with the foot 15 of a person positioned as anticipated on top of the top portion 20.

[0013] As can be seen from viewing FIG. 1, the clip house mounting structure 10 includes a clip mounting member 30 having a clip receiving means 35, an upper portion 40, and a lower portion 45 presenting a substantially planar clip mounting surface 50. The clip house mounting structure 10 further has a horizontal member 55 extending from the lower portion 45 of the clip mounting member 30 to a reinforcing rib 60. The reinforcing rib 60 is connected to a curved side panel 25 or skirt with foot portions 70,75. The foot portions 70,75 cooperate with a portion of the side panel to define a channel 65.

[0014] The improved clip house—rocker panel combination is shown in FIG. 2. Here, the rocker panel 205 comprises a top member 220 connected to a side or skirt 245 at a first junction 225 which is preferably in the form of an elongated rib or channel 230. The show side of the part is facing the left side of the drawing.

[0015] Note that the side portion of the automotive part is connected to the underside 250 of the part through a radiused section or second junction 255. Clip house 260 comprises a generally planar attachment surface 265, through which a stud 270 or the like is placed to fixedly connect the rocker panel to the frame (not shown) of an automobile or truck.

[0016] Top support 275 of the clip house is connected to the first juncture 225 at the location of the channel. An air space 285 is provided between the top side 220 of the rocker panel and the top support of the clip house. This helps to increase the flex of the top side 220. At the same time, stability of the side or skirt 245 of the part is enhanced by attachment of second support 290 to the non-show side of the rocker panel at the radius or second junction 255.

[0017] While the form of apparatus herein described constitutes a preferred embodiment of this invention, it is to be understood that the invention is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.